building Fly cutter tool in Tool library

[sai_tejaRT58C]

Hi actually I want to build a fly-cutting tool to use for my cam machining the length of the cutter should be long as I need it to reach at least 170 mm below the holder can anyone suggest the dimensions of how can I create in the fusion cam and the cutting dia should be large and the but the shaft dia should be small 

[martha.deans]

Hi @sai_tejaRT58C,

You should be able to use a variety of the available tool definitions to accomplish what you want, you may decide to use one of the following definitions based on how you'd like to use the tool. 

A face mill can make the kind of shape you are describing (large cutting diameter, small shaft diameter) and will work with the Face strategy and other 2D (and even some 3D) tool paths.

You can apply a holder (or not) and from your description I think all the necessary parameters should be supported by this tool. 

A form mill will allow you to sketch the profile of the tool you want to create, and then store that custom profile in the tool library. However, this type of tool works with a limited number of available strategies, due to its capacity for non-standard shapes. This might not be a big deal for you as it's a fly cutter, but this type of tool is probably also overkill. 

If neither of those options work for you let me know and we can take a look at some of the others available. 

[sai_tejaRT58C]

Hi @martha.deans ,

Thank you for your help! I’ve created a custom tool based on your advice and currently am in the simulation phase. I have attached Image 1 with the tool's dimensions and Image 2 showing the area we need to machine.

I’ve calculated the feeds and speeds using standard formulas, which give me 80 RPM and 8 mm/min feed rate for the 100mm cutting Diameter. However, I have a few concerns:

1. Tool Dimensions Impact : Could the length and diameter of the shaft affect the machining process? If so, how should I account for it in the simulation?

2. Feeds, Depth of Cut, and Time: The current feed and speed result in a total machining time of around 15 hours, which is too long. Is there any way I can increase the feed rate or the depth of cut to reduce this time? The minimum tool length must be maintained to reach the required machining areas.

I’d appreciate it if you could verify whether the tool dimensions are valid and suggest any changes I can make to improve the machining process without compromising on the quality.

Thanks again!

[hussain740987]

A comprehensive solution to this problem might be:

1. Verifying and setting the profile of the tool
The first step is to set up the profile of the fly cutter properly. In Fusion 360, create a tool that maintains your specified cutting diameter and shaft diameter. Use the Face mill profile as it is suitable for large cutting diameters and small shaft diameters and is compatible with 2D and 3D tool paths.

2. Adjust feed rate and depth of cut to reduce machining time
Now that the machining time is 15 hours with the current feed and speed settings, you can take the following steps to improve it:

Increase the feed rate slightly and experiment with different speeds to reduce machining time.
If possible, increase the depth of each cut, but only on the condition that standard results are obtained according to the length and diameter of the tool.
Tip: You can also chat with other Fusion 360 users on WhatsApp to get more advice from those who have experience with similar processes.

3. Verify by Simulation
Test tool design and feed/speed settings by running a simulation in Fusion 360. This way you can immediately see how length and diameter affect machining quality.

4. Contact the support team
If these settings don't work, consult Fusion 360's customer support team or other services (such as WhatsApp groups) for further guidance. This can give you valuable tips on how to further improve your setup.

In this way, time can be reduced and cutting quality can be maintained while meeting your needs.